Continuous coking refinery methods and apparatus

ABSTRACT

A system for refining hydrocarbon containing materials in a continuous coking mode may provide a pyrolyzer ( 1 ) which may be inclined to effect a liquid seal between a liquid conduction environment ( 6 ) and a gaseous conduction environment ( 7 ). A heat source ( 9 ) may heat the material past the coking point and the system may include a screw or auger ( 10 ) which can continuously remove the coke while simultaneously outputting refined products.

This application is the United States National Stage of InternationalApplication No. PCT/US00/32029, filed Nov. 21, 2000, which claims thebenefit of and priority from U.S. Provisional Application No. 60/167,335filed Nov. 24, 1999, and U.S. Provisional Application No. 60/167,337filed Nov. 24, 1999, the International Application being filed whileeach of the United States Provisional applications were pending; eachhereby incorporated by reference.

I. TECHNICAL FIELD

The present invention relates to methods and apparatus for refiningheavy oils such as in transforming heavy oils into lighter, or higherquality components which are more commercially useful.

II. BACKGROUND ART

Everyone is aware of the importance that oil and other such materialshave on today's world. They represent an important topic from a widerange of perspectives ranging from environmental to economic topolitical. At a chemical level, these materials are significant becausethe substances of which they are composed have hydrogen and carboncontaining molecules whose structure readily yields energy when burned.In some instances the naturally occurring raw materials are already in adesirable state. For example, CH₄, methane a “natural gas”—as its nameimplies—is often available in a preferred chemical composition innature. Some hydrocarbons, however, do not significantly occur in apreferred state in nature.

Fortunately, most hydrocarbon molecules can be easily separated ortransformed through thermal and chemical processes. The transformationand separation, usually done on a larger scale with creation andcollection of the desired species is the process known popularly as a“refining” the material. To the populace, this is what a refinery does;it continuously takes raw, naturally occurring material and refines itinto one or more forms that are more commercially desirable. As but oneexample, the heavier molecules found in bitumen can be split intolighter components through refining processes. From a simplifiedperspective, the process of refining material involves heating andaltering the composition of the fuel materials by distillation, breakingor cracking the longer molecules into shorter ones, driving the variousspecies off as volatile components, and then collecting substances inthe desired form.

Many refining processes produce coke. When hydrocarbons are heated abovecertain temperatures, they can reach a point at which the carbon atomsbind together and form a substance known as coke. Coke can beproblematic because it is a very hard and relatively untransformablesubstance which usually binds to its container when formed. Great painsare often taken in processing relative to coke. For example, there is anewly invented technique to identify the point at which coke mayprecipitously form. This technique, described in PCT Application No.PCT/US00/15950, hereby incorporated by reference, shows great promise.

Coking processes require careful handling. Here, processes are oftenaccomplished in a batch or semi-batch modality. After coke has formed,the container is set apart to jackhammer or otherwise remove the cokefrom it. By its very nature, a true continuous process is difficult toachieve. In addition, because of the larger capital expense of suchhandling, at present only large refineries currently utilize coking asthe principal method of upgrading heavy crude oils. Thus, whiledesirable for efficiency, smaller refineries have not been able topractically utilize coking processes on a commercially viable basis.Since the crude oil supplied to refineries is becoming heavier, thisneed is becoming more acute.

In spite of this need, however, a solution to the precipitous formationof coke and availability of coking processes has not been available tothe degree commercially desired. Certainly the importance of therefining process is well known. There has been a long felt butunsatisfied need for more efficiency, for more availability, and forbetter handling of such processes. In spite of this long felt need, theappropriate process as not been available, however. As the presentinvention shows, through a different approach to the problems, asolution now can exist. Perhaps surprisingly, the present inventionshows not only that a solution is available, it also shows that thesolution is one that from some perspectives can be considered to useexisting implementing arts and elements. By adapting some features fromother fields of endeavor (such as the remediation or toxic wasterecovery fields as mentioned in U.S. Pat. No. 5,259,945), the presentinvention can solve many of the problems long experienced by therefinery field.

To an extent, the present invention can be consider as showing that inthe refining field those skilled in the art may have simply had toolimited a perspective and while there were substantial attempts toachieve the desired goals, those involved failed perhaps because of afailure to appropriately understand the problem of coke formation in theappropriate context. In fact, the efforts may even have taught away fromthe technical direction in which the present inventors went and so theresults might even be considered as unexpected. Thus the presentinvention may represent not merely an incremental advance over the priorart, it may provide a critically different approach which afford theability to utilize coking process while also providing a continuousprocess operation. As will be seen, the physical features which permitthis critical difference in performance are not merely subtleties inbatch-type processing (such as might exist in a semi-batch modality),they are an entirely different way of dealing with the coke and theprocesses. Thus, until present invention no processes provided theability to permit truly continuous, coking processing in thecommercially practical manner now possible.

III. DISCLOSURE OF INVENTION

The present invention provides a continuous refining process whichpermits the intentional formation of coke from the material to beprocessed while acting to separate and perhaps create a greater quantityof refined products. In one embodiment, the invention utilizes aninclined auger with a medium such as sand in which the raw material isheated past the coking point. The auger then continuously moves the cokeout of the bed so that constant and continuous refinement can occur.

Accordingly, it is one of the many goals of the present invention toprovide a system through which continuous refining can occur even whilepermitting coke to form. In achieving such a goal the invention providesrefinement in one system but with multiple zones so that the continuousprocess can be efficiently conducted.

Naturally, further objects of the invention are disclosed throughoutother areas of the specification and claims.

IV. BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic of an inclined auger-type of refining apparatus.

FIG. 2 is a diagram of an output of an embodiment of the presentinvention in one application.

FIG. 3 is a diagram of a hydrotreating result on the pyrolyzer certainoverheads.

FIG. 4 is a schematic of one type of overall system.

FIG. 5 is a diagram of one type of process material

FIG. 6 is a chart of throughput for one embodiment of the presentinvention.

FIG. 7 is an estimate of the cost of processing drilling muds in oneembodiment of the present invention.

V. BEST MODE(S) FOR CARRYING OUT THE INVENTION

As can be seen from the drawings, the basic concepts of the presentinvention may be embodied in many different ways. FIG. 1 shows aschematic of an inclined auger-type of refining apparatus according tothe present invention. This can be considered one of the many keycomponents to an improved refining system. As an important feature ofone embodiment, the system is designed not only to be able to acceptheavy hydrocarbon containing material, it can do it on a continuousbasis. As shown in FIG. 1, the refining apparatus may include apyrolyzer (1) having a process container (5) within which refining canoccur. The pyrolyzer (1) may have some type of input (2) through whichmaterial to be processed may travel. In keeping with one of the goals ofthe invention, the input (1) may be a continuous input such thatmaterial is provided into the pyrolyzer (1) at the same rate at which itis processed. The processing of the material may, of course, result inrefined products which may flow out of an output such as volatilesoutput (3). It may also result in residuum or unrefined or even perhapsunrefinable material. These may flow out through some type of outputsuch as residuum output (4).

As mentioned earlier, an desired aspect of at least one embodiment isthe ability to process heavy hydrocarbon material. By this not only isthe traditional definition of “heavy” intended, but also specific goalssuch as the ability to continuously input a material having an APIgravity of at most about 11° API, heavy oils, asphalts, pitches,bitumens, material having an API gravity of less than about 11° API,material having an API gravity of less than about 10° API, materialhaving an API gravity of less than about 7° API, and even materialhaving an API gravity of less than about 3° API. Further, in oneembodiment, there is also a desire to be able to handle and processmaterials which have significant amounts of residuum, including but notlimited to material having at least 5% by weight residuum, materialhaving at least 7% by weight residuum, material having at least 10% byweight residuum, and even material having at least 15% by weightresiduum or higher.

The pyrolyzer (1) may alter the chemical composition of the material tobe processed. Such may, of course include a variety of crudes, but alsosuch materials as stripper bottoms and the like. For more effectiveprocessing, this may be accomplished through coking and crackingreactions which rearrange the hydrocarbons and redistribute thehydrogen. For example, through an embodiment of the present inventionapplied to the processing of Cold Lake crude, approximately 55% of theflash bottoms fed the stripper were recovered as distillate while 45%flowed as underflow to the pyrolyzer (1). The product off the pyrolyzer(1) can even be a light, residuum-free distillate with an API gravity inthe 25 to 60 degree range. Importantly, the pyrolyzer (1) can produce alight hydrocarbon oil which, once stabilized, can contributesignificantly to overall product value.

Pyrolyzing can include coking and cracking of the heavy oil or materialto produce additional light, residuum-free oil, fuel gas to power theprocess, and a solid similar to petroleum-coke for land-filling.Referring to FIG. 2, in this example, it can be understood that byweight it is estimated approximately 44% of the feed to the pyrolyzer(1) can emerge as liquid, about 12% can emerge as fuel gas and about 44%can emerge as coke. The pyrolyzer (1) can also be used to processsolids, particularly hydrocarbon-laden solids, of course.

In one design, the pyrolyzer (I) can coke approximately 75 bpd of heavyoils or even stripper bottoms at temperatures about 1000° F. Thepyrolyzer (1) can also be combined with other process elements such asstrippers and flashers or the like. Whereas the pyrolyzer alters thechemical composition, the flash and stripping operations may be thermalseparations with a variety of options.

As may be easily understood, the pyrolyzer (1) may achieve the refiningof the hydrocarbon material by utilizing a refining environment and evencontinuously volatilizing substances. The system can then use thosesubstances as or to form refined products. For example, desirednon-condensible gases can be recovered and reused as process fuel or canbe flared. As material progresses further into a hot zone, cracking andcoking of the remaining heavier hydrocarbon may occur. In oneembodiment, this can occur to or even past the coking point, thus agreater amount of recovery and refining can be achieved. Significantly,one system combines a coking type of processing with a continuous inputand continuously inputting the material to be processed, to permitenhanced outputs. Thus, the input (2) to a process container (5) may beadapted to continuously accept material.

It may be important to understand that the system can providedifferential processing. This may occur through use of more than onerefining environment. By this, it should be understood that differentconduction, temperature, locational, flow, or other types of zone can beencompassed. Referring to FIG. 1, it can be understood how a preferredembodiment can have multiple refining environments in yet one processcontainer (5). In this embodiment, the multiple zones are achieved byinclining process container (5) and providing it in a less than fullcondition. As shown, there is a first refining environment such as thetotally liquid conduction environment (6) and a second refiningenvironment such as the totally gaseous conduction environment (7).These environments may establish different thermal environments betweenwhich the temperature, rate of conduction or other thermal differencesmay exist. This may occur over an effective processing length (8) in onecontainer such as the one process container (5).

As shown, after introducing the material through input (2), the refiningor material refinement may be initiated in a first refining environment,shown here as liquid conduction environment (6). It may then be pushed,be pulled, or otherwise travel to continue material refinement in asecond refining environment, shown here as gaseous conductionenvironment (7). After the material is introduced through input (2), itmay be heated by some type of heat source (9). [This may, of course,include a great variety of heat sources and so is shown onlyschematically.] This raises the temperature of the material, and as thattemperature is raised, different volatile substances are driven off.These can be collected through volatiles output (3) as mentionedearlier. Since energy is used to drive off volatiles, as the materialtravels down length (8) of process container (5), it may continue itsheating. This may drive off other volatiles and may cause cracking ofthe heavier hydrocarbons and may eventually reach the point at whichcoke forms for that material, that is, the coke formation temperature.

As shown by the dotted line in FIG. 1, liquid conduction environment (6)eventually terminates and next exists gaseous conduction environment(7). By inclining process container (5), this may exist over a distance.Thus a third refining environment can be considered to exist, here, anenvironment which transitions between purely liquid and gaseous states.Again, as the material travels across the pyrolyzer (1), it can beconsidered as being subjecting to a third refining environment, here,the region in which there is a combination of said first and said secondrefining environments, namely the partially liquid and partially gaseousenvironment. This can afford refining advantages. As can be understood,the third refining environment can considered be a third thermalenvironment or a transition refining environment. Through the inclineddesign shown, this transition environment can present a gradualtransition environment, or even a linear transition environment wherebythe amount of one environment (liquid) linearly decreases while theamount of another environment (gaseous) linearly increases. In thisregion, there is, of course, a combined liquid and gaseous conductionenvironment.

The allocation of the amount and changes in the various processingenvironments can be noteworthy as well. As can be understood from thedrawing, at least about the lower one-third of the processing length (8)or about one-third of the process container (1) may contain the or someof the first refining environment or liquid conduction environment (6).This may also be increased or decreased to other lengths. Particularly,even at least about one-half of the processing length (8) or aboutone-half of the process container (5) may be used for the liquidconduction environment (6). Thus, in an inclined pyrolyzer (1)embodiment, the lower one-third or even lower one-half may be the liquidor un-volatilized material area.

As mentioned earlier, the material being processed may be pushed, bepulled, or otherwise travel in the pyrolyzer (1). It may affirmativelybe accomplished. This moving of the material may be from a firstrefining environment to a second refining environment. As shown a screwor auger (10) may be but one way to accomplish this movement, amongother purposes. The screw or auger (10) may thus serve as a movementelement which operates through the liquid conduction environment (6) andinto the gaseous conduction environment (7). In the arrangement shown,the lower one-third to one-half of the inclined screw can be filled withhot liquid which subsequently cokes and is augered up and out of thesystem.

FIG. 4 is a schematic of an overall system according to one embodimentof the invention. As can be understood, volatiles output (3) may feed[with or without a post-refinement treater (11)] into some type ofcollector, such as a condenser (12). Regardless as to how designed, thecollector usually would act to output the desired refined products.Often, of course this may be done separately, however, for simplicity itis shown conceptually only as a single refined product output (13).These various items would accomplish collecting the refined products orperhaps condensing at least some of the results of the refining process.As envisioned in one preferred embodiment, they would be configured andoperated for collecting refined products having an API gravity of atleast about 25° API, of up to at least about 60° API, or perhaps so thatthe refined products would have an API gravity of at least about 26°API, of no more than about 3.7% sulfur content, of no more than about3.1% sulfur content, or even having the characteristics of a fuel gas.Thus the elements may be adapted to receive at least some of thevolatilized substances created by the refining processes and forcollecting at least some of the refined products.

In order to facilitate the refinement process, a sweep gas may be used.This is shown in FIGS. 1 and 4 where a sweep gas input (14) is depicted.As shown, it may be advantageous to establish the sweep gas input (14)as situated behind the point at which the liquid terminates, an area ofa liquid seal as discussed later. Additionally, of course, the sweep gasoutput, shown as coincident with the volatiles output (3) may beestablished behind the liquid seal as well to facilitate the withdrawalof the refined volatiles.

In heating the material to be processed, it may be highly desirable tointentionally heat that material beyond the coking temperature. Thus,coke will likely be formed. Rather than merely having some incidentalformation of coke, this type of an embodiment of the invention mayintentionally and affirmatively substantially exceed the coke formationtemperature within the material. This will, of course result in exactlythe substance which had previously been considered undesirable in somesystems and may cause the forming of a substantial amount of coke fromat least some of said material (e.g. the material that has not beenvolatilized). High residuum material can thus be used efficiently,including but not limited to material which would result in at leastabout 1%, 2%, 5%, 10%, 20%, or even as mentioned 44% of input materialby weight of coke material. A variety of temperatures may be used toresult in the forming of a substantial amount of coke from at least someof such material. These can include temperatures in which the heatsource (9) is operated as a coke formation heat source to cause thematerial to achieve at least about 650° F., 700° F., 750° F., 800° F.,900° F., 950° F., 1000° F., 1100° F., and even 1200° F. or more.

As mentioned earlier, at least some of the material to be processed maybe moved from input to output. When coke is formed, this element cantake on an additional role. The movement element, shown in FIG. 1 as thescrew or auger (10), may thus operates at least between a continuousinput and a continuous coke output element. Besides operating to augerthe material up the incline of the process container (5), it may serveto force the coke out of the process container (5). As can beappreciated, the movement element may serve to grind, abrade, auger,shearing, break, or otherwise cause the coke formed to be forced out ofthe process container (5). Importantly for one embodiment, the removingof coke may occur while the coke is being formed by the heating of thematerial. It may present a continuous removal process as desired in someembodiments.

The coke, remaining material, or even residuum may then exit thepyrolyzer (1) at a remaining material output such as the residuum output(4). By being able to present a continuous process, the residuum orremaining material may be especially appropriate for disposal. Dependingon the initial material processed and the configuration of the system,it may even present a residuum which cokes substantially (ie. greaterthan 80%, 85%, 90%, 95%, or even 98%) all of the un-volatilized organicmaterial or residuum. Thus, by the time the material leaves thepyrolyzer, nearly all volatile hydrocarbon may have been removed andonly inorganic solids and petroleum coke may remain. Even the remainingcoke may be more appropriate for disposal. A system according to oneembodiment of the present invention may continuously remove or createcoke having no more than about 6.7% sulfur content or even having nomore than about 3.7% sulfur content. Thus the screw or auger (10) mayserve as a continuous coke output element and the system may operate toform coke out of substantially all un-volatilized organic material.Obviously, when the system can be designed so that the coke formationheat source operates to form coke out of substantially all residuum, anoptimal situation may exist.

In understanding how the screw or auger (10) may serve as a continuouscoke output element, it should be appreciated that such an arrangementis but one way to configure the system. As one of ordinary skill in theart would readily appreciate, many other way are possible including butnot limited utilizing a coke grinder, a coke abrader, a coke auger, acoke shear element, a coke break element, or many other types ofelements. Importantly from the perspective of efficiency, the outputelement may be operated while the coke formation heat source acts toform coke and may serve as a continuous coke output element to which theremaining material is responsive. Again, the inclined screw arrangementis merely one representative design.

To promote the desired heat transfer, the pyrolyzer (1) can include afluidized bed of hot sand such as sand bed (15) as a high conductionenergy transfer element. As is well known, the sand bed (15) may have agas feed (18) to enhance conduction. Into the bed may be immersed therotary screws. Incoming material to be processed may be fed into thesescrews and augered into the hot zone of the pyrolyzer. As the materialis heated within the screw, it can evolve light hydrocarbon vapors whichmay be removed, condensed and recovered as liquid hydrocarbon product.The system may then accomplish outputting of the residuum of material orthe coke through residuum output (4). The remaining coke may be disposedof. By using the sand bed (15) as a high conduction energy transferelement, proper processing can be facilitated. For example, the heat maybe transferred at a rate to properly establish a first thermalenvironment within which material may be processed. By establishing asecond thermal environment which differs from the first environment,heat may be transferred differentially. For example, by establishing aliquid conduction environment there may be a greater conduction of heatin that environment than in the gaseous conduction environment. The highconduction energy transfer element which may be effective over aneffective process length (as one example, a length in which the refiningoccurs and is significantly influenced by the heat source) may thus becoordinated with the one or more refinery characteristics (e.g., heat ofheat transfer, speed of the screw, amount of heat supplied, etc.) topresent an optimal system. As mentioned, the pyrolyzer can use afluidized bed of hot sand into which rotary screws are immersed,however, this should understood as only one type of highly conductingenergy design.

In embodiments utilizing an incline, the material may be moved on anincline such as that shown to exist within process container (5) as itmoves from input (2) to an output. Thus the system may present aninclined refinement process area. Correspondingly, there may be aninclined movement element to which the material is responsive, such asthe inclined screw or auger (10) depicted within the inclined refinementprocess area. The incline may also serve to create a seal between thevolatiles and the input (2). As shown, the pyrolyzer (1) may have aninput end top (16) and an output end bottom (17) which differ in levelheight. This may serve to create a totally liquid area and a totallygaseous area to facilitate sealing.

The amount of the incline may vary with the amount and type of materialbeing process, the geometry of the system, and other factors. As but oneexample, an angle of at least about: 15°, 22.5°, 30°, and 45° may serveto achieve the desired sealing and refining operations. Further, allthat may be necessary is that the output end bottom (17) besubstantially higher than said input end top (16) so that blow back ofthe volatiles does not occur. Additionally, the incline should not be sosteep that the coke or other remaining material cannot pass up theincline through operation of the movement element such as screw or auger(10). Thus the movement element may serve as an incline overpowermovement element so that the refining of the material occurs on theincline creating refined products perhaps throughout that element andmoves in a manner which overcomes the effects of the incline. The outputend bottom (17) may even be substantially above said liquid level sothat once can be certain only coke, and not unprocessed material isremoved.

In such a configuration, the unit's throughput can also be determined byeither the reaction kinetics or the rate of heat transfer. Since thelower portion of the screw can be liquid-filled, heat transfer in thisregion can be rapid on the process side and can be controlled by theconvective heat transfer on the gas side of the screw. The use of afluidized bed on the gas side can also lead to very rapid heat transferto the screw, thus, in service the pyrolyzer throughput can becontrolled by the kinetics of the coking reactions. The length, speed,and other process parameters can thus be set based upon a variety offactors, including but not limited to the amount of thermal transfer inapparatus, the speed at which said apparatus is operated, the amount ofheat supplied in the apparatus, the amount of thermal transfer in thegaseous conduction environment, the amount of thermal transfer in thehigh conduction energy transfer element, the kinetics of cokingreactions occurring within the refinery apparatus, etc.

Through providing an inclined process area, an advantage in sealing thesystem can be achieved. As shown in FIG. 1, the input end top (16) ofpyrolyzer (1) is higher than the output end bottom (17). This can beappreciated from the level line (19) which represents the level theliquid would tend to achieve under static conditions. Depending upon thespeed at which screw or auger (10) operates, some liquid may, of courseachieve a higher level toward the output end bottom (17). In a cokingmodality, one goal may be to avoid having any fluid reach the residuumoutput (4) so that only coke or other remainder is output from thesystem. This can be achieved by the incline creating a totally gaseousarea on the output end. In addition, the incline can serve to create atotally liquid area on the input end to facilitate sealing the volatilespresent at volatiles output (3) from pushing back and exiting out input(2). Much like a liquid trap, the incline is one way to establish aliquid seal between the input (2) and the output. Instead of providing aseparate element to achieve the seal, the present invention utilizes atleast some of the material to be processed as a more efficient system. Avariety of levels of seal are possible, of course including but notlimited to: at least about a 1 psi seal, at least about a 2 psi seal, aseal having at least 2 feet of liquid head or depth, a seal having atleast 1 foot of liquid head, a seal located about mid way between theinput and output, and a seal adequate to avoid blow back of the resultsfrom continuously volatilizing substances. As can be appreciated, theseal may be established at an interface between the material and thevolatilized substances. In creating the seal, the incline serves toestablish a seal-creation inclined refinement process area. It is alsomade up of and utilizes the input or hydrocarbon material.

As will be easily understood by those of ordinary skill in the art, thematerial being refined by pyrolyzer (1) may be treated before it goesinto the pyrolyzer (1) and after it conies out from the pyrolyzer (1).Such steps and elements are shown schematically in FIG. 4. In a broadersense, the step of pre-treating the material, of course occurs beforeaccomplishing the continuous volatilization of substances and may beaccomplished by one or more types of a pretreater (20).

Some of the types of functions which may be used include, but are notlimited to: thermal treating, flashing, stripping, and the variouspermutations and combinations of these and other steps. Considering thepyrolyzer (1) as the focus refinery apparatus, this refinery apparatusis responsive to the various pretreatment elements whether they be athermal treater, a flasher, a stripper, or the like. As shown in FIG. 4,both a flasher (21) and a stripper (22) are shown as utilized in thisone embodiment.

As can be appreciated from FIG. 4, the flow of material is fromunprocessed material source (23) to refined product output (13). As partof the particular pretreater (20) depicted, both a flasher (21) and astripper (22) are utilized. The stripper (22) may be an atmosphericdistillation unit with the solids agitated by a stripper sweep gasprovided through a stripper sweep gas feed (24) to bubble through thestill. In addition to providing agitation, this gas may also lower thepartial pressures of the distilling hydrocarbons thus achieving some ofthe advantages of a vacuum still. The nature of the oil or otherhydrocarbons fed to the stripper (22) (particularly its boiling pointcurve and specific gravity) can have a significant influence on theamount of product taken off the stripper (22) in stripper output (25) aswell as the pyrolyzer (1) and the quality of that product. Varying theoperating temperature of stripper (22) may produce greater or lesseramounts of distillate in the overhead with the balance reporting withthe residuum to the stripper bottoms. These stripper bottoms may be fedto the pyrolyzer (1). Using the Cold Lake crude as an example, it isestimated that approximately 55% of the crude will be recovered asdistillate from the stripper as a 20.2 deg API oil having a sulfurcontent of 2.9 weight percent. Then the refined product off thepyrolyzer (1) can be a light, residuum-free distillate with an APIgravity in the 25 to 60 degree range. The entire stripper operation canof course be varied. This may include a variety of steps including butnot limited to: atmospherically distilling, bubbling a sweep gas throughmaterial, both atmospherically distilling and bubbling a sweep gasthrough the material, creating at least about some 20° API material,creating at least about some 60° API material, and the permutations andcombinations of each of these. Thus the stripper (22) may include anatmospheric distiller, a sweep gas feed (24), and both of these.

As shown in FIG. 4, the pretreater (20) may also include elements toflash the material. This is shown generically as flasher (21). Assummarized in FIG. 5, feed to one type of process material can consistof a mixture of oil, water and suspended solids. In processing suchmaterial, the mixture may be first heated under pressure to temperaturesnear 400° F., and then expanded through a flash valve to atmosphericpressure. This is a type of flashing with a sudden let-down in pressureto release the emulsified water as steam. This may be vented harmlesslyto the stack (26). The warm flash bottoms can then be sent to thestripper (22) where the first product oil or other refined product canbe recovered. The act of flashing the material can, of course beaccomplished before accomplishing the step of continuously volatilizingsubstances. It may also be greatly varied and may include the steps of:heating the material to at least about 400° F., rapidly reducing thepressure of the heated material to about atmospheric pressure, and bothof these. The unit, depicted generically as flasher (21) will thenoutputs at least some heavy hydrocarbon material for the refineryapparatus. Thus elements used may include a heat source which operatesto achieve a material temperature of at least about 400° F., a pressurereducer, and generically an atmospheric flasher.

Treating the refined products of pyrolyzer (1) may also be included. Asshown this may be accomplished generically by a post-refinement treater(11). As its name implies, it may be configured to permit post-treatingafter the refined products of pyrolyzer (1) are created and may belocated either before or after condenser (12). At least some of thevolatilized substances may be fed into it and so the post-refinementtreater (11) may be responsive to the refinery apparatus. One type ofpost-refinement treating may be hydrotreating such as wherepost-refinement treater (11) includes or serves as a hydrotreater. Thechart in FIG. 3 is a summary of some hydrotreating results obtained onpyrolyzer overheads in the example. The sample labeled “Untreated 2” andthe one labeled “Stripper Oil” were the samples discussed earlier. Theremaining samples were generated during a test from an original materialwhich is labeled “Untreated 1”. The bromine number and diene value bymaleic anhydride are empirical indications of the presence of olefins(bromine number) and conjugated dienes (dienes by maleic anhydride). Themaleic anhydride value does not directly reflect the concentrations ofdienes in the sample because the mass of each individual sample and themolality of the titrant is required for this calculation. Similarly, thediene value is an indication of conjugated double bonds and subject tointerference from species such as anthracene and other polynucleararomatic hydrocarbons which are abundant in these oils. As a result, theabsolute significance of these values should be interpreted withcaution.

The hydrotreating accomplished in this example is a hydrotreating of therefined products at least about 1800 psi through a pressure element(depicted as part of the pretreater) capable of achieving that pressure.From the result shown in FIG. 3, it is shown that hydrotreating at 1800psi can lead to low hydrogen consumption, significantly reduced oreliminated olefin concentrations, an acceptable H/C ratio, and operatingconditions conducive to maximum catalyst life. If some residual olefinsdo remain, these may not be highly reactive and it will likely not benecessary to saturate them in order to prevent gum formation. Inaddition, the extreme ease of cracking and subsequent resaturationsuggests an alternate configuration where all material is first sent tothe pyrolyzer and then hydrotreated so as to produce maximum quantitiesof light product oil for condensate replacement, blending and sale.

Efficient energy utilization and hydrogen management can be valuable tothe self-sustaining design's thermal efficiency and low operating costs.The pyrolyzer can produce a light hydrocarbon oil which, oncestabilized, can contribute significantly to overall product value. Thehydrogen required to achieve this stabilization and to hydrotreatadditional stripper overhead can also be derived from the coking of aportion of the stripper bottoms. In so doing, petroleum coke suitablefor fueling the pyrolyzer may be produced. The remaining products, C₁ toC₄ hydrocarbons, may be sold as product. Overall, all of the incomingmaterial can be converted to high value products or consumed as fuel.

On a BS&W-free basis, the process in the example can be configured to becapable of recovering approximately 80–85% of the original hydrocarbonas product oil with the remaining material split between process fuelgas and coke. On an overall process basis, and as but one example,processing the Cold Lake crude with the present invention process canproduce 16,404 bpd of 26.5 deg API product oil containing 3.67% sulfur,712 tons per day of coke containing 6.7% sulfur, and 6.18 MM scf/day offuel gas with a HHV of 1328 Btu/scf. Of course, these processing stepshave applications similar to those in a modern refinery. As a result,the technology, with appropriate variations and upgrades, is ideallysuited for deployment in the oil fields as a mobile, modular,shop-fabricated refinement.

For further efficiency, the system may be designed to return some oreven all the energy needed to run the process. It may be self sustainingby utilizing energy generated from the refined products in the method ofrefining. This may be accomplished by combusting non-condensible refinedproducts generated in the method, among other returns. Thus the systemmay utilize substantially no input power to power the steps of themethod of refining. In the schematic of FIG. 4, the energy reuse element(27) is conceptually shown as utilizing some output from stripper output(25) to return energy to the refinery apparatus (depicted as returningas heat input to pyrolyzer (1). It may also be wise to use somenon-condensible refined products combustion element (depicted as part ofthe energy reuse element) to facilitate the energy return.

Plant example:

-   -   Cold Lake bitumen. An example of a 20,000 b/d plant processing        the Cold Lake bitumen, an 11° API crude containing 4.6% sulfur        is used to illustrate the principles involved in one approach.        Upgrading this crude may produce 16,404 bpd of a 26.5° API        product containing 3.1% sulfur by weight. The plant additionally        may produce 712 tons/day of coke (6.74% S) and 6.2 MMscf/day of        fuel gas having a HHV of 1328 Btu/scf. The facility may require        no import power or fuel and would likely have an operating cost        (exclusive of capital related charges) of less than        Cdn$0.65/bbl. Capital costs for such a facility and others like        it may be determined in partnership with heavy oil producers and        the assignee of the present invention. However, based upon        experience and estimates of the National Center for Upgrading        Technology in Devon, Alberta, a total capital investment of Cdn        $98.2 million for facilities and an operating cost, including        capital costs, of Cdn $2.66 per barrel may be achieved. Of this,        $2.02 are capital related charges and so a figure of this nature        may be included as well. In this example, the process may also        be configured to produce coke and fuel gas and may use no import        power.

Although a different application, drilling muds and other challengingmaterials can be processed as well. In a powered system, gas andelectric charges may be approximately $3.25/ton assuming power at 5¢/kWh and natural gas at $2.25/Mcf. As much as 30 gallons of diesel oilcan be recovered per ton of material processed. This has been creditedto the process at $10/ton after allowance for waste solid disposal bylandfilling with operating labor, assumed to be $40/hour for twooperators/shift around the clock. Capital charges can be estimated to be15% of total capital investment. Although preliminary, these economicssuggest that processing charges of $30/ton or less should be possiblefor reasonable ranges of specific capital investment and for reasonableplant operating factors.

In this different type of application, namely that not for a continuousrefinement of supplied heavy oils but rather that of thermally removinghydrocarbon from drilling muds or other such waste products, heattransfer can be arranged to be rapid from the fluidized bed to the shellof the screw and vaporization can be nearly instantaneous onceevaporation temperatures are reached. In this instance, the material inthe screw can be either a mud or a damp solid with a resultant processside heat transfer coefficient which might be considerably lower thanthat of the earlier case. Here the overall throughput may be controlledby the rate of heat transfer from the shell of the inclined screw to theinterior mass of damp solid on the process side. Such individual heattransfer coefficients and their effects on any such process or theoverall heat transfer may need to be measured experimentally. Thus itcan be seen that the present invention may apply to, but not be limitedto, heavy oils from crude oil and any other mixtures of hydrocarbonproducts, water and sediments. Although perhaps of less commercialsignificance it may be used to transform waste materials such as tankbottom wastes and drilling muds. Such a use of some components of thepresent invention can be for waste material recovery as discussed in aU.S. Pat. No. 5,259,945, hereby incorporated by reference. This process,referred to as “TaBoRR” processing (a trademark of the assignee), is aprocess of recovering distilled and upgraded oil from mixtures of oil,water and sediments. The economics of processing such drilling muds orthe like in a pyrolyzer of the present invention is preliminarilyestimated in the chart in FIG. 3. Specific capital investment may dependupon the heat transfer coefficients determined during the experimentalprogram, but are expected to vary between 0.1 to 1 $MM/ton/hour.

As can be easily understood from the foregoing, the basic concepts ofthe present invention may be embodied in a variety of ways. It involvesboth refining techniques as well as devices to accomplish theappropriate refining. In this application, the refining techniques aredisclosed as part of the results shown to be achieved by the variousdevices described and as steps which are inherent to utilization. As buta few examples, the refining techniques may be used in, but not limitedto, heavy oil upgrading, tar sand processing, production pits, crude oilrefining, and other small or large refineries. They are simply thenatural result of utilizing the devices as intended and described. Inaddition, while some devices are disclosed, it should be understood thatthese not only accomplish certain methods but also can be varied in anumber of ways. Importantly, as to all of the foregoing, all of thesefacets should be understood to be encompassed by this disclosure.

The discussion included in this patent is intended to serve as a basicdescription. The reader should be aware that the specific discussion maynot explicitly describe all embodiments possible; many alternatives areimplicit. It also may not fully explain the generic nature of theinvention and may not explicitly show how each feature or element canactually be representative of a broader function or of a great varietyof alternative or equivalent elements. Again, these are implicitlyincluded in this disclosure. Where the invention is described indevice-oriented terminology, each element of the device implicitlyperforms a function. Apparatus claims may not only be included for thedevice described, but also method or process claims may be included toaddress the functions the invention and each element performs. Neitherthe description nor the terminology is intended to limit the scope ofthe claims available to the applicant.

It should also be understood that a variety of changes may be madewithout departing from the essence of the invention. Such changes arealso implicitly included in the description. They still fall within thescope of this invention. A broad disclosure encompassing both theexplicit embodiment(s) shown, the great variety of implicit alternativeembodiments, and the broad methods or processes and the like areencompassed by this disclosure. It should be understood that suchdisclosure may cover numerous aspects of the invention bothindependently and as an overall system.

In addition, unless the context requires otherwise, it should beunderstood that the term “comprise” or variations such as “comprises” or“comprising”, are intended to imply the inclusion of a stated element orstep or group of elements or steps but not the exclusion of any otherelement or step or group of elements or steps. Such terms should beinterpreted in their most expansive form so as to afford the applicantthe broadest coverage legally permissible.

Further, each of the various elements of the invention and claims mayalso be achieved in a variety of manners. This disclosure should beunderstood to encompass each such variation, be it a variation of anembodiment of any apparatus embodiment, a method or process embodiment,or even merely a variation of any element of these. Particularly, itshould be understood that as the disclosure relates to elements of theinvention, the words for each element may be expressed by equivalentapparatus terms or method terms—even if only the function or result isthe same. Such equivalent, broader, or even more generic terms should beconsidered to be encompassed in the description of each element oraction. Such terms can be substituted where desired to make explicit theimplicitly broad coverage to which this invention is entitled. As butone example, it should be understood that all actions may be expressedas a means for taking that action or as an element which causes thataction. Similarly, each physical element disclosed should be understoodto encompass a disclosure of the action which that physical elementfacilitates. Regarding this last aspect, as but one example, thedisclosure of a “stripper” should be understood to encompass disclosureof the act of “stripping”—whether explicitly discussed or not—and,conversely, were there only disclosure of the act of “stripping”, such adisclosure should be understood to encompass disclosure of a “stripper”and even a “means for stripping” Such changes and alternative terms areto be understood to be explicitly included in the description.

In addition, as to each term used it should be understood that unlessits utilization in this application is inconsistent with suchinterpretation, common dictionary definitions should be understood asincorporated for each term, and all definitions, alternative terms, andsynonyms such as contained in the Random House Webster's UnabridgedDictionary, Second Edition are hereby incorporated by reference.Finally, all references in the disclosure or listed in the list ofReferences to be Incorporated filed with the application are appendedhereto and hereby incorporated by reference as well as the earlierpriority application, U.S. Applications Nos. 60/167,335 and 60/167,337(with their incorporated references) and any other references mentionedin the application for this patent as well as all references listed inany list of references to be incorporated filed with the present and/orearlier application are hereby incorporated by reference in theirentirety. However, to the extent statements might be consideredinconsistent with the patenting of this/these invention(s) suchstatements are expressly not to be considered as made by theapplicant(s). Additionally, the applicant(s) should be understood tohave support to claim the various combinations and permutations of eachof the elements disclosed.

LIST OF REFERENCES

I. U.S. Patent Documents

DOCUMENT NO DATE NAME FILING DATE 5,259,945 Nov. 9, 1993 Johnson, Jr. etal Apr. 15, 1992 5,653,865 Aug. 5, 1997 Miyasaki Nov. 6, 1995 5,755,389May 26, 1998 Miyasaki Mar. 19, 1997II. Foreign Patent Documents

DOCUMENT NO DATE COUNTRY 2,153,395 Feb. 9, 1999 Canada PCT/US00/15950Sep. 6, 2000 PCTIII. Other Documents

U.S. patent application Ser. No. 60/167,337, “Methods and Apparatus forHeavy Oil Upgrading”, filed Nov. 24, 1999. U.S. patent application Ser.No. 60/167,335, “Methods and Apparatus for Improved Pyrolysis ofHydrocarbon Products”, filed Nov. 24, 1999. U.S. patent application Ser.No. 60/138,846, “Predicting Proximity to Coke Formation”, filed Jun. 10,1999.

1. A method of refining heavy hydrocarbon material comprising the stepsof: a. continuously inputting a material containing at least some heavyhydrocarbon material; b. heating said material; c. continuouslyvolatilizing substances from said material to form refined products; d.collecting at least some of said refined products; e. substantiallyexceeding a coke formation temperature within said material; f. forminga desired form of coke from at least some of said material in a singleprocess container; g. continuously removing said coke; h. establishing afirst thermal environment within which material is processed; and i.establishing a second thermal environment within which material isprocessed; wherein said step of establishing a first thermal environmentwithin which material is processed comprises the step of establishing aliquid conduction environment, and wherein said step of establishing asecond thermal environment within which material is processed comprisesthe step of establishing a gaseous conduction environment.
 2. A methodof refining heavy hydrocarbon material as described in claim 1 whereinsaid step of substantially exceeding a coke formation temperature withinsaid material comprises the step of at least achieving about atemperature selected from a group consisting of: 650° F., 700° F. 750°F., 800° F., 900° F., 950° F., 1000° F., 1100° F., and 1200° F.
 3. Amethod of refining heavy hydrocarbon material as described in claim 2wherein said step of continuously inputting a material containing atleast some heavy hydrocarbon material comprises the step of continuouslyinputting material selected from a group consisting of: heavy oil,asphalt, pitch, bitumen, material having an API gravity of less thanabout 11° API, material having an API gravity of less than about 10°API, material having an API gravity of less than about 7° API, materialhaving an API gravity of less than about 3° API, material havingsignificant amounts of residuum, material having at least 5% by weightresiduum, material having at least 7% by weight residuum, materialhaving at least 10% by weight residuum, and material having at least 15%by weight residuum.
 4. A method of refining heavy hydrocarbon materialas described in claim 2 wherein said step of forming coke from at leastsome of said material comprises the step of forming a substantial amountof coke from said material.
 5. A method of refining heavy hydrocarbonmaterial as described in claim 4 wherein said step of forming asubstantial amount of coke from said material comprises the step offorming an amount of coke from said material selected from a groupconsisting of at least about: 1% of said input material by weight ofcoke material, 2% of said input material by weight of coke material, 5%of said input material by weight of coke material, 10% of said inputmaterial by weight of coke material, 20% of said input material byweight of coke material, and 44% of said input material by weight ofcoke material.
 6. A method of refining heavy hydrocarbon material asdescribed in claim 4 wherein said step of forming a substantial amountof coke from said material comprises the step of forming coke fromsubstantially all un-volatilized organic material.
 7. A method ofrefining heavy hydrocarbon material as described in claim 4 wherein saidstep of forming a substantial amount of coke from said materialcomprises the step of forming coke from substantially all residuum.
 8. Amethod of refining heavy hydrocarbon material as described in claim 2and further comprising the step of moving at least some material frominput to output.
 9. A method of refining heavy hydrocarbon material asdescribed in claim 2 wherein said step of continuously removing saidcoke comprises a process selected from a group consisting of: grindingsaid coke, abrading said coke, angering said coke, shearing said coke,and breaking said coke.
 10. A method of refining heavy hydrocarbonmaterial as described in claim 2 wherein said step of continuouslyremoving said coke occurs while accomplishing said step of forming cokefrom at least some of said material.
 11. A method of refining heavyhydrocarbon material as described in claim 2 and further comprising thestep of moving said material on an incline from input to an output. 12.A method of refining heavy hydrocarbon material as described in claim 2and further comprising the step of establishing a liquid seal between aninput and an output.
 13. A method of refining heavy hydrocarbon materialas described in claim 12 wherein said step of establishing a liquid sealbetween an input and an output comprises the step of utilizing at leastsome of said material containing at least some heavy hydrocarbonmaterial.
 14. A method of refining heavy hydrocarbon material asdescribed in claim 13 wherein said step of establishing a liquid sealbetween an input and an output comprises the step of establishing aliquid seal selected from a group consisting of: at least about a 1 psiseal, at least about a 2 psi seal, a seal having at least 2 feet ofliquid head, a seal having at least 1 foot of liquid head, a seallocated about mid way between an input and an output, a seal adequate toavoid blow back of the results of said step of continuously volatilizingsubstances.
 15. A method of refining heavy hydrocarbon material asdescribed in claim 2 wherein said step of collecting at least some ofsaid refined products comprises the step of condensing at least some ofthe results of said step of continuously volatilizing substances.
 16. Amethod of refining heavy hydrocarbon material as described in claim 15wherein said step of collecting at least some of said refined productscomprises the step of collecting refined products having an API gravityselected from a group consisting of: at least about 25° APT, up to atleast about 60° API.
 17. A method of refining heavy hydrocarbon materialas described in claim 2, 11, 12, or 15 and further comprising the stepof pre-treating said material containing at least some heavy hydrocarbonmaterial before accomplishing said step of continuously volatilizingsubstances from said material to form refined products.
 18. A method ofrefining heavy hydrocarbon material as described in claim 17 whereinsaid step of pre-treating said material containing at least some heavyhydrocarbon material before accomplishing said step of continuouslyvolatilizing substances from said material to form refined productscomprises a step selected from a group consisting of: thermal treatingsaid material, flashing said material, stripping said material, and thepermutations and combinations of each.
 19. A method of refining heavyhydrocarbon material as described in claim 17 wherein said step ofpre-treating said material containing at least some heavy hydrocarbonmaterial before accomplishing said step of continuously volatilizingsubstances from said material to form refined products is selected froma group consisting of: atmospherically distilling said material,bubbling a sweep gas through said material, both atmosphericallydistilling said material and bubbling a sweep gas through said material,creating at least about some 20° API material, creating at least aboutsome 60° API material, and the permutations and combinations of each.20. A method of refining heavy hydrocarbon material as described inclaim 17 and further comprising the step of flashing said materialbefore accomplishing said step of continuously volatilizing substancesfrom said material to form refined products.
 21. A method of refiningheavy hydrocarbon material as described in claim 20 wherein said step offlashing said material before accomplishing said step of continuouslyvolatilizing substances from said material to form refined products isselected from a group consisting of: heating said material to at leastabout 400° F., rapidly reducing the pressure of said heated material toabout atmospheric pressure, and both heating said material to at leastabout 400° F. and rapidly reducing the pressure of said heated materialto about atmospheric pressure.
 22. A method of refining heavyhydrocarbon material as described in claim 17 and further comprising thestep of post-treating said refined products after they are created. 23.A method of refining heavy hydrocarbon material as described in claim 22wherein said step of post-treating said refined products after they arecreated comprises the step of hydrotreating said refined products afterthey are created.
 24. A method of refining heavy hydrocarbon material asdescribed in claim 23 wherein said step of hydrotreating said refinedproducts after they are created comprises the step of hydrotreating saidrefined products at least about 1800 psi.
 25. A method of refining heavyhydrocarbon material as described in claim 23 and further comprising thesteps of: a. condensing at least some of the results of said step ofcontinuously volatilizing substances; and b. pre-treating said materialcontaining at least some heavy hydrocarbon material before accomplishingsaid step of continuously volatilizing substances from said material toform refined products selected from a group consisting of: thermaltreating said material, flashing said material, stripping said material,and the permutations and combinations of each.
 26. A method of refiningheavy hydrocarbon material as described in claim 2, 11, 12, or 15 andfurther comprising the step of utilizing energy generated from saidrefined products in said method of refining.
 27. A method of refiningheavy hydrocarbon material as described in claim 26 wherein said thestep of utilizing energy generated from said refined products in saidmethod of refining comprises the step of combusting non-condensiblerefined products generated in said method.
 28. A method of refiningheavy hydrocarbon material as described in claim 27 and furthercomprising the step of utilizing substantially no input power to powerthe steps of said method of refining.
 29. A method of refining heavyhydrocarbon material as described in claim 27 wherein said step ofcollecting at least some of said refined products comprises the step ofcondensing at least some of the results of said step of continuouslyvolatilizing substances, and further comprising the step of pre-treatingsaid material containing at least some heavy hydrocarbon material beforeaccomplishing said step of continuously volatilizing substances fromsaid material to form refined products by accomplishing a step selectedfrom a group consisting of: thermal treating said material, flashingsaid material, stripping said material, and the permutations andcombinations of each.
 30. A method of refining heavy hydrocarbonmaterial as described in claim 2 wherein said step of continuouslyinputting a material containing at least some heavy hydrocarbon materialcomprises the step of continuously inputting a material having an APIgravity of at most about 11° API.
 31. A method of refining heavyhydrocarbon material as described in claim 2 wherein said step ofcontinuously removing said coke comprises the step of continuouslyremoving coke selected from a group consisting of: coke having no morethan about 3.7% sulfur content, and coke having no more than about 6.7%sulfur content.
 32. A method of refining heavy hydrocarbon material asdescribed in claim 2 wherein said refined products have characteristicsselected from a group consisting of: an API gravity of at least about26° API, no more than about 3.7% sulfur content, no more than about 3.1%sulfur content, the characteristics of a fuel gas, and the permutationsand combinations of each.
 33. A method of differentially refining heavyhydrocarbon material comprising the steps of: a. inputting a materialcontaining at least some heavy hydrocarbon material; b. heating saidmaterial; c. initiating material refinement in a first refiningenvironment; d. continuing material refinement in a second refiningenvironment; e. collecting at least some of said refined products; andf. outputting a residuum of said material, wherein said step ofinitiating material refinement in a first refining environment comprisesthe step of establishing a liquid conduction environment, and whereinsaid step of continuing material refinement in a second refiningenvironment comprises the step of establishing a gaseous conductionenvironment.
 34. A method of differentially refining heavy hydrocarbonmaterial as described in claim 33 wherein said step of heating saidmaterial comprises the step of substantially exceeding a coke formationtemperature within said material.
 35. A method of differentiallyrefining heavy hydrocarbon material as described in claim 33 whereinsaid step of substantially exceeding a coke formation temperature withinsaid material comprises the step of at least achieving about atemperature selected from a group consisting of: 650° F., 700° F., 750°F., 800° F., 900° F., 950° F., 1000° F., 1100° F., and 1200° F. andwherein said step of inputting a material containing at least some heavyhydrocarbon material comprises the step of continuously inputtingmaterial selected from a group consisting of: heavy oil, asphalt, pitch,bitumen, material having an API gravity of less than about 11° API,material having an API gravity of less than about 10° API, materialhaving an API gravity of less than about 7° API, material having an APIgravity of less than about 3° API, material having significant amountsof residuum, material having at least 5% by weight residuum, materialhaving at least 7% by weight residuum, material having at least 10% byweight residuum, and material having at least 15% by weight residuum.36. A method of differentially refining heavy hydrocarbon material asdescribed in claim 33 and further comprising the step of subjecting saidmaterial to a third refining environment.
 37. A method of differentiallyrefining heavy hydrocarbon material as described in claim 36 whereinsaid step of subjecting said material to a third refining environmentcomprises the step of utilizing a refining environment which is acombination of said first refining environment and said second refiningenvironment.
 38. A method of differentially refining heavy hydrocarbonmaterial as described in claim 36 wherein said step of subjecting saidmaterial to a third refining environment comprises the step of utilizinga transition refining environment which transitions between said firstrefining environment and said second refining environment.
 39. A methodof differentially refining heavy hydrocarbon material as described inclaim 38 wherein said step of utilizing a transition refiningenvironment which transitions between said first refining environmentand said second refining environment comprises the step of utilizing atransition refining environment selected from a group consisting of: agradual transition environment and a linear transition environment. 40.A method of differentially refining heavy hydrocarbon material asdescribed in claim 33 wherein said step of initiating materialrefinement in a first refining environment comprises the step ofestablishing a first thermal environment within which material isprocessed and wherein said step of continuing material refinement in asecond refining environment comprises the step of establishing a secondthermal environment within which material is processed.
 41. A method ofdifferentially refining heavy hydrocarbon material as described in claim36 wherein said steps of initiating material refinement in a firstrefining environment, continuing material refinement in a secondrefining environment, and subjecting said material to a third refiningenvironment each comprise the step of establishing different thermalenvironments.
 42. A method of differentially refining heavy hydrocarbonmaterial as described in claim 36 wherein said step of initiatingmaterial refinement in a first refining environment comprises the stepof establishing a liquid conduction environment, wherein said step ofcontinuing material refinement in a second refining environmentcomprises the step of establishing a gaseous conduction environment, andwherein said step of subjecting said material to a third refiningenvironment comprises the step of establishing an environment combiningboth a liquid conduction environment and a gaseous conductionenvironment.
 43. A method of differentially refining heavy hydrocarbonmaterial as described in claim 42 wherein said step of substantiallyexceeding a coke formation temperature within said material comprisesthe step of at least achieving about a temperature selected from a groupconsisting of: 650° F., 700° F., 750° F., 800° F., 900° F., 950° F.,1000° F., 1100° F., and 1200° F. and wherein said step of inputting amaterial containing at least some heavy hydrocarbon material comprisesthe step of continuously inputting material selected from a groupconsisting of: heavy oil, asphalt, pitch, bitumen, material having anAPT gravity of less than about 11° API, material having an API gravityof less than about 10° API, material having an API gravity of less thanabout 7° API, material having an API gravity of less than about 3° API,material having significant amounts of residuum, material having atleast 5% by weight residuum, material having at least 7% by weightresiduum, material having at least 10% by weight residuum, and materialhaving at least 15% by weight residuum.
 44. A method of differentiallyrefining heavy hydrocarbon material as described in claim 33 whereinsaid steps of establishing a liquid conduction environment andestablishing a gaseous conduction environment both occur in a processcontainer having an effective process length and wherein said step ofestablishing a liquid conduction environment comprises the step ofestablishing a liquid conduction environment in a location selected froma group consisting of: about one-third of said process container, aboutone-half of said process container, about a lower one-third of saidprocess container, and about a lower one-half of said process container.45. A method of differentially refining heavy hydrocarbon material asdescribed in claim 40 wherein said steps of establishing a first thermalenvironment within which material is processed and establishing a secondthermal environment within which material is processed both occur in aprocess container having an effective process length and furthercomprising the step of coordinating said effective process length with arefinery characteristic selected from a group consisting of: the amountof thermal transfer in said apparatus, the speed at which said apparatusis operated, the amount of heat supplied in said apparatus, the amountof thermal transfer in said gaseous conduction environment, the amountof thermal transfer in an energy transfer element, the kinetics ofcoking reactions occurring within said refinery apparatus, and thepermutations and combinations of each.
 46. A method of differentiallyrefining heavy hydrocarbon material as described in claim 45 whereinsaid effective process length comprises at least a coke formationlength.
 47. A method of differentially refining heavy hydrocarbonmaterial as described in claim 33 or 45 and further comprising the stepsof: a. forming coke from at least some of said material; and b.continuously removing said coke.
 48. A method of differentially refiningheavy hydrocarbon material as described in claim 33 or 45 and furthercomprising the step of moving said material from an input to an output.49. A method of differentially refining heavy hydrocarbon material asdescribed in claim 48 wherein said step of moving said material from aninput to an output comprises the step of moving said material up anincline between said input and said output.
 50. A method ofdifferentially refining heavy hydrocarbon material as described in claim49 wherein said step of moving said material up an incline between saidinput and said output comprises the step of angering said material upsaid incline.
 51. A method of differentially refining heavy hydrocarbonmaterial as described in claim 48 wherein said step of moving saidmaterial from an input to an output comprises the step of moving saidmaterial from said first refining environment to said second refiningenvironment.
 52. A method of differentially refining heavy hydrocarbonmaterial as described in claim 33 or 45 and further comprising the stepof establishing a liquid seal between an input and an output.
 53. Amethod of differentially refining heavy hydrocarbon material asdescribed in claim 52 wherein said step of establishing a liquid sealbetween an input and an output comprises the step of utilizing at leastsome of said heavy hydrocarbon material.
 54. A method of differentiallyrefining heavy hydrocarbon material as described in claim 53 whereinsaid step of establishing a liquid seal between an input and an outputcomprises the step of establishing a liquid seal selected from a groupconsisting of: at least about a 1 psi seal, at least about a 2 psi seal,a seal having at least 2 feet of liquid head, a seal having at least 1foot of liquid head, a seal located about mid way between an input andan output, a seal adequate to avoid blow back of refined material.
 55. Amethod of refining hydrocarbon material comprising the steps of: a.inputting a material containing at least some hydrocarbon material; b.heating said material; c. refining said material on an incline whilecreating refined products; and d. outputting said refined products;wherein said step of refining said material on an incline while creatingrefined products comprises the steps of: a. establishing a first thermalenvironment within which material is processed; and b. establishing asecond thermal environment within which material is processed; whereinsaid step of establishing a first thermal environment within whichmaterial is processed comprises the step of establishing a liquidconduction environment, and wherein said step of establishing a secondthermal environment within which material is processed comprises thestep of establishing a gaseous conduction environment.
 56. A method ofrefining hydrocarbon material as described in claim 55 wherein said stepof heating said material comprises the step of substantially exceeding acoke formation temperature within said material.
 57. A method ofrefining hydrocarbon material as described in claim 56 wherein said stepof substantially exceeding a coke formation temperature within saidmaterial comprises the step of at least achieving about a temperatureselected from a group consisting of: 650° F., 700° F., 750° F., 800° F.,900° F., 950° F., 1000° F., 1100° F., and 1200° F. and wherein said stepof inputting a material containing at least some hydrocarbon materialcomprises the step of continuously inputting material selected from agroup consisting of: heavy hydrocarbon material, heavy oil, asphalt,pitch, bitumen, material having an API gravity of less than about 11°API, material having an API gravity of less than about 10° API, materialhaving an API gravity of less than about 7° API, material having an APIgravity of less than about 3° API, material having significant amountsof residuum, material having at least 5% by weight residuum, materialhaving at least 7% by weight residuum, material having at least 10% byweight residuum, and material having at least 15% by weight residuum.58. A method of refining hydrocarbon material as described in claim 55wherein said step of refining said material on an incline while creatingrefined products comprises the step of refining said material on anincline having an input top and an output bottom and wherein said outputbottom is higher than said input top.
 59. A method of refininghydrocarbon material as described in claim 55 wherein said step ofrefining said material on an incline while creating refined productscomprises the step of refining said material on an incline having anincline selected from a group consisting of: an incline of at leastabout 15°, an incline of at least about 22.5°, an incline of at leastabout 30°, and an incline of at least about 45°.
 60. A method ofrefining hydrocarbon material as described in claim 58 wherein saidmaterial has a liquid level and wherein said output bottom issubstantially above said liquid level.
 61. A method of refininghydrocarbon material as described in claim 55 wherein said step ofrefining said material on an incline while creating refined productscomprises the step of establishing a liquid seal between an input and anoutput through action of said incline.
 62. A method of refininghydrocarbon material as described in claim 61 wherein said step ofestablishing a liquid seal between an input and an output through actionof said incline comprises the step of utilizing said hydrocarbonmaterial.
 63. A method of refining hydrocarbon material as described inclaim 62 wherein said step of establishing a liquid seal between aninput and an output comprises the step of establishing a liquid sealselected from a group consisting of: at least about a 1 psi seal, atleast about a 2 psi seal, a seal having at least 2 feet of liquid head,a seal having at least 1 foot of liquid head, a seal located about midway between an input and an output, a seal adequate to avoid blow backof said refined products.
 64. A method of refining hydrocarbon materialas described in claim 55 wherein said step of refining said material onan incline while creating refined products comprises the step of movingsaid material in a manner which overcomes the effects of said incline.65. A method of refining hydrocarbon material as described in claim 55,59, 61, or 63 and further comprising the steps of: a. forming coke fromat least some of said material; and b. continuously removing said coke.66. A method of refining hydrocarbon material as described in claim 55,59, or 61 and further comprising the step of establishing a liquid sealbetween an input and an output.
 67. A method of refining hydrocarbonmaterial as described in claim 66 wherein said step of establishing aliquid seal between an input and an output comprises the step ofutilizing at least some of said hydrocarbon material.
 68. A method ofrefining hydrocarbon material as described in claim 55 and furthercomprising the step of highly conducting energy into said material. 69.A method of refining hydrocarbon material as described in claim 68wherein said step of highly conducting energy into said materialcomprises the step of utilizing an energy transfer element selected froma group consisting of: a fluidized bed, an energy transfer elementhaving a conduction value of at least about 5 btu/hr/ft²/F°, an energytransfer element having a conduction value of at least about 20btu/hr/ft²/F°, an energy transfer element having a conduction value ofat least about 50 btu/hr/ft²/F°, and an energy transfer element having aconduction value of at least about 100 btu/hr/ft²/F°.
 70. A method ofrefining hydrocarbon material as described in claim 68 wherein said stepof highly conducting energy into said material comprises the step ofutilizing a sand bed and a gas feed.
 71. A method of refininghydrocarbon material comprising the steps of: a. inputting a materialcontaining at least some hydrocarbon material; b. heating said material;c. establishing a liquid seal between an input and an output; and d.outputting refined products.
 72. A method of refining hydrocarbonmaterial as described in claim 71 wherein said step of heating saidmaterial comprises the step of substantially exceeding a coke formationtemperature within said material.
 73. A method of refining hydrocarbonmaterial as described in claim 72 wherein said step of substantiallyexceeding a coke formation temperature within said material comprisesthe step of at least achieving about a temperature selected from a groupconsisting of: 650° F., 700° F., 750° F., 800° F., 900° F., 950° F.,1000° F., 1100° F., and 1200° F. and wherein said step of inputting amaterial containing at least some hydrocarbon material comprises thestep of continuously inputting material selected from a group consistingof: heavy hydrocarbon material, heavy oil, asphalt, pitch, bitumen,material having an API gravity of less than about 11° API, materialhaving an API gravity of less than about 10° API, material having an APIgravity of less than about 7° API, material having an API gravity ofless than about 3° API, material having significant amounts of residuum,material having at least 5% by weight residuum, material having at least7% by weight residuum, material having at least 10% by weight residuum,and material having at least 15% by weight residuum.
 74. A method ofrefining hydrocarbon material as described in claim 71 wherein said stepof establishing a liquid seal between an input and an output comprisesthe step of utilizing at least some of said hydrocarbon material.
 75. Amethod of refining hydrocarbon material as described in claim 74 andfurther comprising the step of outputting residuum.
 76. A method ofrefining hydrocarbon material as described in claim 71 or 74 whereinsaid step of establishing a liquid seal between an input and an outputcomprises the step of establishing a liquid seal selected from a groupconsisting of: at least about a 1 psi seal, at least about a 2 psi seal,a seal having at least 2 feet of liquid head, a seal having at least 1foot of liquid head, a seal located about mid way between an input andan output, a seal adequate to avoid blow back of the results of saidstep of continuously volatilizing substances.
 77. A method of refininghydrocarbon material as described in claim 76 wherein said step ofheating said material comprises the step of at least achieving about atemperature selected from a group consisting of: 650° F., 700° F., 750°F., 800° F., 900° F., 950° F., 1000° F., 1100° F., and 1200° F. andwherein said step of inputting a material containing at least somehydrocarbon material comprises the step of continuously inputtingmaterial selected from a group consisting of: heavy hydrocarbonmaterial, heavy oil, asphalt, pitch, bitumen, material having an APIgravity of less than about 11° API, material having an API gravity ofless than about 10° API, material having an API gravity of less thanabout 7° API, material having an API gravity of less than about 3° API,material having significant amounts of residuum, material having atleast 5% by weight residuum, material having at least 7% by weightresiduum, material having at least 10% by weight residuum, and materialhaving at least 15% by weight residuum.
 78. A method of refininghydrocarbon material as described in claim 71 and further comprising thesteps of: a. inputting a sweep gas above said liquid seal; and b.outputting said sweep gas above said liquid seal.
 79. A method ofrefining hydrocarbon material as described in claim 71 and furthercomprising the steps of: a. forming coke from at least some of saidmaterial; and b. continuously removing said coke.
 80. A method ofrefining hydrocarbon material as described in claim 71 wherein said stepof heating said material comprises the steps of: a. establishing a firstthermal environment within which material is processed; and b.establishing a second thermal environment within which material isprocessed.
 81. A method of refining hydrocarbon material as described inclaim 80 wherein said step of establishing a first thermal environmentwithin which material is processed comprises the step of establishing aliquid conduction environment, and wherein said step of establishing asecond thermal environment within which material is processed comprisesthe step of establishing a gaseous conduction environment.
 82. A methodof refining hydrocarbon material as described in claim 71 and furthercomprising the step of moving said material from an input to an output.83. A method of refining hydrocarbon material as described in claim 82wherein said step of moving said material from an input to an outputcomprises the step of moving said material up an incline between saidinput and said output.
 84. A method of refining hydrocarbon material asdescribed in claim 83 wherein said step of moving said material up anincline between said input and said output comprises the step ofaugering said material up said incline.
 85. A method of refininghydrocarbon material as described in claim 82 wherein said step ofmoving said material from an input to an output comprises the step ofmoving said material from a first refining environment within a processcontainer to a second refining environment within said processcontainer.
 86. A method of refining heavy hydrocarbon materialcomprising the steps of: a. continuously inputting a material containingat least some heavy hydrocarbon material; b. heating said material; c.continuously volatilizing substances from said material to form refinedproducts; d. collecting at least some of said refined products; c.substantially exceeding a coke formation temperature within saidmaterial; f. forming a desired form of coke from at least some of saidmaterial in a single process container; g. continuously removing saidcoke; and h. establishing a liquid seal between an input and an output.87. A method of differentially refining heavy hydrocarbon materialcomprising the steps of: a. inputting a material containing at leastsome heavy hydrocarbon material; b. heating said material; c. initiatingmaterial refinement in a first refining environment; d. continuingmaterial refinement in a second refining environment; e. collecting atleast some of said refined products; and f. outputting a residuum ofsaid material; and g. establishing a liquid seal between an input and anoutput.
 88. A method of refining hydrocarbon material comprising thesteps of: a. inputting a material containing at least some hydrocarbonmaterial; b. heating said material; c. refining said material on anincline while creating refined products; and d. outputting said refinedproducts; wherein said step of refining said material on an inclinewhile creating refined products comprises the step of establishing aliquid seal between an input and an output through action of saidincline.
 89. A method of refining hydrocarbon material comprising thesteps of: a. inputting a material containing at least some hydrocarbonmaterial; b. heating said material; c. refining said material on anincline while creating refined products; and d. outputting said refinedproducts; and e. establishing a liquid seal between an input and anoutput.
 90. A method of refining hydrocarbon material as in claim 89wherein said step of refining said material on an incline while creatingrefined products comprises the step of refining said material on anincline having an incline selected from a group consisting of: anincline of at least about 15°, an incline of at least about 22.5°, anincline of at least about 30°, and an incline of at least about 45°. 91.A method of refining hydrocarbon material as in claim 89 wherein saidstep of refining said material on an incline while creating refinedproducts comprises the step of establishing a liquid seal between aninput and an output through action of said incline.
 92. A method ofrefining heavy hydrocarbon material as described in claim 2 and furthercomprising the step of flashing said material before accomplishing saidstep of continuously volatilizing substances from said material to formrefined products.
 93. A method of refining heavy hydrocarbon material asdescribed in claim 2 and further comprising the step of post-treatingsaid refined products after they are created.